Apparatus and method for rotating cylindrical members and coating internal surface of tubulars

ABSTRACT

Methods and systems comprising a first and a second powder coating apparatus, with each apparatus comprising a tubular barrel having an axial bore extending longitudinally therethrough, are usable for coating an interior surface of a tubular member. Each coating apparatus comprises a conical member connected with the tubular barrel and at least one gas conduit connected to the tubular barrel for communicating gas into the tubular barrel. The at least one gas conduit contains a gas flow control valve connected thereto for controlling the volumetric flow rate of gas through the at least one gas conduit. Each coating apparatus further comprises at least one container for holding a coating material, an inlet conduit for communicating the coating material into the axial bore of the tubular barrel, and a plurality of gas nozzles connected to the tubular barrel for inducing spiraling gas flow through the axial bore of the tubular barrel.

This application is a Divisional of U.S. patent application Ser. No.14/687,710, filed on Apr. 15, 2015. The disclosure of the priorapplication is hereby incorporated by reference herein in its entirety.

FIELD

The present invention relates generally to powder coating apparatus andmethods of use, and more specifically, to apparatus and methods usablefor rotating cylindrical members and coating the internal surfaces ofthe cylindrical members, including tubulars, pipe and the like.

BACKGROUND

Coating the inside of tubular members or tubulars, such as oilfieldpipe, is well known in the art. Coating the inside of the tubular, byapplying a material to the inside diameter or inside surface of thetubular which has been heated previously, is used to prevent corrosionand erosion of the inside surface. Additionally, pipe are often coatedin order to reduce friction of the inside surface, as pipe that havebeen coated require less pressure to pump fluid therethrough, due to thereduced friction.

With recent advances in material science and increased demand for deeperand wider wells, downhole pipe lengths and diameters are increasing. Theincreased pipe lengths have limited the usefulness of prior coatingdevices, as these coating devices are unable to provide a uniforminterior coating over an extended pipe length or a large pipe diameter.Despite the improvements in powder coating technology, problems ofuneven coating thickness or gaps of bare metal on the inside surface oftubular goods have persisted.

Some existing devices have relied on introducing an excessive amount ofcoating material in order to ensure that the entire interior surface iscoated. This procedure includes a thick application of material to theinterior of the tubular, which can result in a coating layer that is toothick at one end and too thin at the opposite end. Furthermore, theseexisting coating devices are not adjustable to tubulars having differentlengths and/or diameters. As such, each different pipe size or lengthrequires a different volumetric flow rate therethrough, during coatingoperations, to maintain the desired powder velocities through the pipefor optimal coating formation.

Changes in pressure within the pipe during coating operations can alsocause changes in the velocity of the coating material particles. A thickcoating at the load end can result, where the particles have a longdwell or residence time upon initial loading. In addition, justdownstream of the load end, a zone of reduced coating thickness canresult from the sudden increase in particle velocity. Further, a zone ofincreasing coating thickness, toward the discharge end of the pipe, canresult as the velocity of the particles through the pipe is reduced dueto friction and decreased pressure. If increased air pressure is used tocompensate for this action, the powder particles will have a greatervelocity and will tend to pass through the discharge end withoutsufficient residence time to melt on the pipe wall, resulting in yetanother zone of decreased film thickness. The number of bare metal gapsalso tends to increase within the zone of decreased coating or filmthickness.

Additionally, weld splatter inside the tubulars, which are manufacturedwith welded seams, is a common source of coating problems. Specifically,as some weld splatter is not removed when the pipe is cleaned prior toapplying the coating, the splatter becomes part of the interior of thetubulars. Previous methods and devices for applying coating to theinsides of tubulars are unable to sufficiently cover the bumps andcavities caused by weld splatter because of the improper rates oftubular rotation or improper powder velocities through the tubular.

Yet another drawback of previous devices is that they were unable toensure constant rotation speeds for variously sized pipe. These previousdevices are not automatically adjustable to tubulars having differentdiameters, wherein each differently sized diameter of the tubulars canrotate at a different speed to cause non-uniform rotation andapplication.

A further drawback of previous devices is that they rely on a humanoperator for controlling each step of the coating operations, whichresults in significant time delays over extended periods of operation.

Therefore, as the previous devices are totally or partially ineffectiveand deficient in coating the inside surface of tubulars, there is a needto provide improved apparatus and methods for uniformly applying apowdered coating material to the interior of tubulars, regardless of thediameter and/or length of the tubulars.

There is a need for providing a coating device that is adjustable todifferent tubular diameters, wherein the coating device can be adjustedto supply the necessary volumetric air flow rates into the tubulars togenerate and maintain desired powdered coating material velocitiesduring coating operations over the entire length of the tubulars,including tubulars having an extended length.

There is a need in the art for providing a coating device which rotatestubulars, no matter what their diameter, at a constant, predeterminedspeed.

There is also a need for providing a coating device that can automateeach step of the coating operations, minimizing time delays between eachphase of the coating operations.

Embodiments usable within the scope of the present disclosure meet theseneeds.

SUMMARY

The present disclosure is directed to a system for coating an interiorsurface of a tubular member. An embodiment of the system can comprise afirst coating apparatus and a second coating apparatus, each comprisingan elongated barrel having a first end, a second end, and an axial boreextending longitudinally therethrough. Each coating apparatus canfurther comprise a conical member connected with the elongated barrel atthe first end thereof, and a plurality of gas conduits connected to theelongated barrel. The conical members can connect with an end of thetubular member, and the plurality of gas conduits can communicatepressurized gas into the axial bore of the elongated barrel. Each gasconduit can further contain a gas flow control valve connected theretofor controlling the flow of gas through the gas conduit, wherein eachflow control valve can control the flow of gas through each gas conduitindependently from the other flow control valve. Each coating apparatuscan comprise a first container for holding therein a coating material,an inlet conduit connected to the elongated barrel, and a plurality ofgas nozzles connected to the elongated barrel. The inlet conduit cancommunicate the coating material from the first container into the axialbore of the elongated barrel and the inlet conduit can be connected tothe elongated barrel between the plurality of gas conduits and the firstend of the elongated barrel. The plurality of gas nozzles can introducepressurized gas into the axial bore of the elongated barrel to induce aspiraling gas flow through the axial bore, toward the first end of theelongated barrel. The spiraling gas flow can cause the coating materialto spiral as the coating material moves through the axial bore and thetubular member.

The present disclosure is further directed to a system for moving androtating cylindrical members during coating and cleaning operations. Anembodiment of the system comprises a first rotator apparatus and asecond rotator apparatus positioned at a distance from each other. Eachof the first and the second rotator apparatus can comprise a first wheelhaving a first axis of rotation and a second wheel having a second axisof rotation, wherein the first and second axes of rotation can begenerally parallel. Each of the first and second rotators can furthercomprise an arm positioned adjacent the first and second wheels, whereinthe arm can extend generally perpendicularly with respect to the firstand second axes of rotation and can have a downwardly sloping upperedge. Each arm can receive a cylindrical member thereon and can move inan upward and/or downward direction. When moving in the downwarddirection, each arm can position the cylindrical member between thefirst and second wheels. When moving in the upward direction, each armcan move the cylindrical member from between the first and secondwheels.

The present disclosure is further directed to a method for moving androtating tubular members during coating and cleaning operations. Themethod can comprise the steps of providing a first rotator apparatus,comprising a first set of wheels and a first arm positioned adjacent tothe first set of wheels, and providing a second rotator apparatus,comprising a second set of wheels and a second arm positioned adjacentto the second set of wheels. Each of the first arm and second arms canhave an upper edge that can be downwardly sloping. The method canfurther comprise the steps of positioning a tubular member on the firstand second upper edges, rolling the tubular member along the first andsecond upper edges from a first side of the first and second arms towardthe second side of the first and second arms, and stopping the tubularmember from rolling along the first and second arms at an intermediateposition between the first and second sides of the first and secondarms. Further steps can include moving the first and second arms in adownward direction to position the tubular member in contact with thefirst and second sets of wheels, rotating the first and second sets ofwheels to rotate the tubular member, moving the first and second arms inan upward direction to lift the tubular member off of the first andsecond wheels, and rolling the tubular member along the first and secondupper edges, toward the second end of the first and second arms, forremoval from the first and second rotator apparatus.

The present disclosure is directed also to methods for coating aninterior surface of a tubular member. The methods can comprise the stepsof capturing the tubular member between a first conical member and asecond conical member, rotating the tubular member, establishing aswirling air flow through the first tubular barrel with a plurality ofnozzles positioned along the tubular barrel, and drawing air from thesecond tubular barrel with a vacuum generator. Further method steps caninclude introducing coating material into the first tubular barrel,whereby the swirling air flow moves the coating material through thetubular member in a swirling manner, communicating air into the firsttubular member through an air conduit that can be connected to the firsttubular member, upstream from the plurality of nozzles, to move thecoating material through the tubular member to coat the tubular member;and adjustably controlling the volumetric flow rate of the aircommunicated into the first tubular member through the air conduit.

The foregoing is intended to give a general idea of the invention, andis not intended to fully define nor limit the invention. The inventionwill be more fully understood and better appreciated by reference to thefollowing description and drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

In the detailed description of various embodiments usable within thescope of the present disclosure, presented below, reference is made tothe accompanying drawings, in which:

FIG. 1 depicts an isometric view of an embodiment of a powder coatingsystem in accordance with the present disclosure.

FIG. 2A depicts a close-up isometric view of a pipe rotator of thepowder coating system depicted in FIG. 1.

FIG. 2B depicts a close-up isometric view of another pipe rotator of thepowder coating system depicted in FIG. 1.

FIG. 2C depicts an exploded view of the pipe rotator depicted in FIG.2B.

FIG. 3A depicts a top isometric view of an embodiment of a first coatingapparatus of the powder coating system depicted in FIG. 1.

FIG. 3B depicts a bottom isometric view of the first coating apparatusdepicted in FIG. 3A.

FIG. 3C depicts a schematic drawing of the first coating apparatusdepicted in FIGS. 1,3A, and 3B.

FIG. 4 depicts a cross sectional axial view of an embodiment of acoating barrel in accordance with the present disclosure.

FIG. 5 depicts a cross sectional top view of an embodiment of thecoating barrel in accordance with the present disclosure.

One or more embodiments are described below with reference to the listedFigures.

DETAILED DESCRIPTION OF THE EMBODIMENTS

Before describing selected embodiments of the present disclosure indetail, it is to be understood that the present invention is not limitedto the particular embodiments described herein. The disclosure anddescription herein is illustrative and explanatory of one or morepresently preferred embodiments and variations thereof, and it will beappreciated by those skilled in the art that various changes in thedesign, organization, means of operation, structures and location,methodology, and use of mechanical equivalents may be made withoutdeparting from the spirit of the invention.

As well, it should be understood that the drawings are intended toillustrate and plainly disclose presently preferred embodiments to oneof skill in the art, but are not intended to be manufacturing leveldrawings or renditions of final products and may include simplifiedconceptual views to facilitate understanding or explanation. As well,the relative size and arrangement of the components may differ from thatshown and still operate within the spirit of the invention.

Moreover, it will be understood that various directions such as “upper”,“lower”, “bottom”, “top”, “left”, “right”, “first”, “second” and soforth are made only with respect to explanation in conjunction with thedrawings, and that components may be oriented differently, for instance,during transportation and manufacturing as well as operation. Becausemany varying and different embodiments may be made within the scope ofthe concept(s) herein taught, and because many modifications may be madein the embodiments described herein, it is to be understood that thedetails herein are to be interpreted as illustrative and non-limiting.

Referring now to FIG. 1, an embodiment of a powder coating system (10)in accordance with the present disclosure is shown. The powder coatingsystem (10) is shown comprising a first and a second coating apparatus(100 a, 100 b), positioned at opposite ends of the powder coating system(10), and three pipe rotating apparatus, referred to as rotators (50a-c), positioned between the first and second coating apparatus (100 a,100 b). The coating apparatus (100 a, 100 b) and the rotators (50 a-c)are shown positioned on a support frame (20), which supports and guidesthe motion of the coating apparatus (100 a, 100 b) and the rotators (50a-c) relative to each other. As further shown in FIG. 1 and explainedbelow, during pipe coating operations, a length of pipe (9), or othertubular member, can be positioned on top of the rotator rollers (56) ofthe rotators (50 a-c). Thereafter, the coating apparatus (100 a, 100 b)can move toward the pipe (9), and along the support frame (20), untileach end of the pipe (9) is sealingly engaged within the opposing cones(115) of each coating apparatus (100 a, 100 b).

The rollers (56) can then rotate the pipe (9) while the first coatingapparatus (100 a) injects a first packet of powdered coating material(not shown), referred to from hereon as the coating material, into thepipe (9). Once the coating material travels the length of the pipe (9),the second coating apparatus (100 b) can inject another packet ofcoating material into the opposite end of the pipe (9), wherein thesecond packet of coating material can travel through the pipe. After thecoating cycles are complete, the coating apparatus (100 a, 100 b) canseparate, allowing the pipe (9) to be removed and another pipe to bepositioned for coating.

Referring still to FIG. 1, the support frame (20) is depicted comprisinga plurality of longitudinal beams (21) and cross beams (22) adapted tosupport and guide the motion of the coating apparatus (100 a, 100 b) andthe rotators (50 a-c). Specifically, portions of the longitudinal beams(21) can comprise rails (23) or other longitudinal protrusions extendingtherefrom, which can be adapted to engage with the wheels (53, 113) ofthe coating apparatus (100 a, 100 b) and the third rotator apparatus (50c). The wheels (53, 113) can, therefore, roll along the support frame(20), wherein the rails (23) retain in position and guide the rollingmotion of the wheels, enabling limited and/or guided movement betweenthe coating apparatus (100 a, 100 b) and the third rotator (50 c).

In other embodiments (not shown) of the powder coating system (10), thesupport frame (20) can guide the wheels (53, 113) by way of longitudinalchannels that are incorporated along the longitudinal beams (21),wherein the channels guide the rolling motion of the wheels (53, 113).In yet another embodiment (not shown) of the powder coating system (10),the longitudinal beams (21) themselves can directly support and guidewheels that are adapted to be rolled thereon. In still anotherembodiment (not shown) of the powder coating system (10), the rails (23)or channels can extend the entire length of the support frame (20),allowing the first and second coating apparatus (100 a, 100 b) and thethree rotators (50 a-c) to move along any portion of the frame (20).

The support frame (20) is shown further comprising toothed bars (24),extending longitudinally between the longitudinal beams (21). Thetoothed bars (24) are depicted extending about half the length of theframe (20), below the third rotator (50 c) and the second coatingapparatus (100 b). As explained herein, the toothed bars (24) are usablefor moving the third rotator (50 c) along the frame (20) when engaged byrotating gears of the corresponding drive assembly (85, see FIG. 2C). Inanother embodiment (not shown) of the powder coating system (10), thetoothed bars (24) can extend the entire length of the support frame(20), allowing the drive assemblies ((85), shown in FIG. 2C) of thefirst and second coating apparatus (100 a, 100 b) and the three rotators(50 a-c) to engage the toothed bars (24) to move the first and secondcoating apparatus (100 a, 100 b) and the three rotators (50 a-c) alongthe frame (20).

The powder coating system (10), depicted in FIG. 1, is shown comprisinga first, second, and third rotators (50 a-c), wherein each rotator cancomprise the same or similar structure and/or function. For clarity, thepresent description and figures will often reference a singleidentifying numeral when describing parts and/or elements of a rotatorhaving the same or similar structure and/or function. For example, FIG.1 depicts a powder coating system (10) comprising three rotators (50a-c) (e.g., subsystems), which comprises roller assemblies (55) havingrollers (56). The rotators (50 a-c) further comprise an arm (70) forloading and unloading the pipe (9) onto and from between the rollers(56), wherein the arm is depicted as a vertical plate, with an upperedge (71) having a slight angle or slope with respect to the ground.Because in the depicted embodiment of the powder coating system (10),the rollers (56) can comprise the same and/or similar structure and/orfunction, all of the rollers (56) will be identified by the same numeralin the description and the drawings for clarity. Similarly, because inthe depicted embodiment of the powder coating system (10) the first andsecond coating apparatus (100 a, 100 b) comprise parts and/or elements,having the same or similar structure and/or function, such parts and/orelements will be identified by the same numeral in the description andthe drawings for clarity.

Referring now to FIG. 2A, the Figure shows a close-up view of anembodiment the first rotator (50 a) in accordance with the presentdisclosure. Specifically, the first rotator (50 a) is shown comprisingtwo sets of roller assemblies (55), each comprising a pair of rollers(56) connected to an electrical motor (57) by a gearbox (58), which canreduce the speed of the rollers (56), while increasing the torque of therollers (56) to enable the rotation of both light and heavy tubulars (9)positioned on top of or between the rollers (56). As further depicted inFIG. 2A, each roller assembly (55) is shown connected to a mountingplate (54) by two support plates (59). Each mounting plate (54) isfurther depicted positioned on opposing sides of a linear slide (60),which enable the roller assemblies (55) to move toward and away fromeach other to accommodate small and large pipe, which are to bepositioned on top of or between the rollers (56) of opposing rollerassemblies (55). The linear slide (60) can be mounted directly to thelongitudinal beams (21) of the frame (20) or by using a transition or amounting plate (53).

The first rotator (50 a) is further depicted comprising an arm (70) forloading and unloading a pipe (9) onto and from between the rollers (56).In FIG. 2A, the arm is depicted as a vertical plate having a first end(70 a), a second end (70 b), and an upper edge (71) having a slightangle, or a slope, with respect to the ground (2). The arm (70) cancomprise a protrusion (72), located adjacent to the second end (70 b) ofthe upper edge (71). During coating operations, the protrusion (72) canmaintain a pipe on the upper edge (71) of the arm and/or prevent thepipe from rolling off of the arm (70). The arm (70) can further comprisea wedge shaped protrusion referred to as an extending member (73)positioned about the upper edge (71), adjacent the space between theroller assemblies (55). The extending member (73) is depicted comprisinga sloping upper edge (75) and a side edge (74), which can be adapted toprevent the pipe (9) from rolling. The portion of the extending member(73) closest to the first end (70 a) of the arm (70) is shown being evenwith the upper edge (71), while the opposite end of the extending member(73), closest to the second end (70 b) of the arm (70), extends abovethe upper edge (71) to form the surface of the side edge (74), which canmaintain a pipe (9) in position during coating operations. The arm (70)can be moved vertically toward and away from the frame (20) by aplurality of fluid cylinders (77). The end cap portions of the cylinders(77) are shown mounted to the longitudinal beams (21) while the cylinderrods are shown connected to the arm (70) with lateral brackets (76)connected to the arm (70).

As shown in FIG. 1, the first rotator (50 a) can be fixedly positionedon the support frame (20) in close proximity to the first coatingapparatus (100 a), while the second rotator (506) can be fixedlypositioned on the support frame (20) at an intermediate position betweenthe first and third rotators (50 a, 50 c), wherein the second rotator(50 b) can support an intermediate portion of the pipe (9). In anembodiment of the powder coating system (10), the second rotator (506)can have a substantially similar or same structure and function and cancomprise substantially similar or the same elements as the first rotator(50 a), described above.

The third rotator (50 c), depicted in FIGS. 1, 2B, and 2C, is showncomprising a similar structure and function as the first and secondrotators (50 a, 50 b). Specifically, the third rotator (50 c) is showncomprising roller assemblies (55), a linear slide (60), and a verticallymovable arm (70), having a structure and function substantially similaror the same as the previously described first and second rotators (50 a,50 b). Unlike the first and second rotators (50 a, 50 b), FIG. 2B showsthe third rotator (50 c) comprising cylinders (77) and a linear slide(60) fixedly connected to a rotator frame assembly (80), not thelongitudinal beams (21) of the support frame. The rotator frame assembly(80) can comprise a plurality of beams (81) supporting the cylinders(77) and the linear slide (60) thereon. The rotator frame assembly (80)further comprises a plurality of wheels (53) rotatably connected to thebeams (81). Similarly to the wheels (113) of the coating apparatus (100a, 100 b), rotator wheels (53) can be adapted to engage the rail (23) toroll along the frame (20).

Furthermore, the third rotator (50 c) can be actuated to roll along theframe (20) by a drive assembly (85), depicted in FIG. 2C showing anexploded view of the third rotator (50 c). The drive assembly (85) isshown comprising a drive axle (87) having a gear (88) on each end,wherein the drive axle can be connected to an electrical motor (89) by agearbox (86), which can reduce the speed of the gears (88), whileincreasing the output torque at the gears (88). FIG. 2C further showsthe gears (88) engaging the toothed bar (24), whereupon energizing themotor (89), the third rotator (50 c) can be moved along the frame (20)towards or away from the second rotator (50 b).

Referring again to FIG. 2C, the Figure further shows the structure ofthe linear slide assembly (60). Specifically, FIG. 2C shows the linearslide (60) comprising guide rods (61) having a plurality of mountingbrackets (62) positioned thereon for slidably connecting the mountingplates (54) to the linear slide (60). The roller assemblies (55) can beactuated to move toward or away from each other along the linear slide(60) by a drive assembly (65). As further depicted in FIG. 2C, the driveassembly (65) is shown comprising a worm gear (67) extending paralleland adjacent to the guide rods (61), and through a complementary tappedthroughbore in the guide mounting brackets (62), wherein rotation of theworm gear (67) can move or translate the mounting brackets (62) and themounting plates (54) along the guide rods (61). The worm gear (67) canbe connected to an electrical motor (68) by a gearbox (66), which canreduce the rotating speed of the worm gear (67), while increasing thetorque of the worm gear (67) to move the roller assemblies (55). Aspreviously stated, the linear slide assembly (60) and the drive assembly(65), as described, can be incorporated into the first and secondrotators (50 a, 50 b) to move the corresponding roller assemblies (55)toward and away from each other to accommodate smaller and largertubulars.

Referring again to FIG. 1, the Figure further depicts the first andsecond coating apparatus (100 a, 100 b) of the powder coating system(10) as comprising a frame assembly (110) that can be usable to maintainthe individual components and subsystems of each coating apparatus (100a, 100 b) in relative position. The frame assembly is depictedcomprising a plurality of horizontal and vertical beams, wherein the tophorizontal beam supports the fluid bed (160) and the storage hopperassembly (200). The lowermost horizontal beams contain the plurality ofwheels (113) for rolling each coating apparatus (100 a, 100 b) along thesupport frame (20). Each coating apparatus (100 a, 100 b) can furthercomprise a linear actuator, such as a fluid powered cylinder, positionedbetween the frame assembly (110) and the support frame (20), which canbe usable to move each coating apparatus (100 a, 100 b) along thesupport frame (20). In an embodiment of the powder coating system (10),a cap end of each fluid powered cylinder can be connected to a portionof the support frame (20), while the rod end can be connected to theframe assembly (110), whereby extending or retracting the cylinder canmove the coating apparatus (100 a, 100 b) along the support frame (20).

FIG. 1 shows oppositely positioned rotatable cones (115), wherein thewide open ends of cones (115) can face each other to receive therein andseal against the pipe (9). It should be noted that the shape of thecones (115) allows various pipe of different sizes to be containedtherein, and to connect the pipe to the front end of the coating barrel(120, see FIG. 3A). Referring also to FIGS. 3A and 3B, the Figures showtop and bottom isometric views of the first coating apparatus (100 a),while FIG. 3C depicts a schematic view of the first coating apparatus(100 a) in accordance with the present disclosure. The narrow ends ofthe first cone (115) are shown connected to a rotating joint (116),which can comprise internal radial bearings (not shown) to allow freerotation of the cone (115), while being connected to the coating barrel(120). Because the coating apparatus (100 a, 100 b) are movable alongthe frame (20), the cones (115) can receive therein and seal againstpipe of various lengths. When the pipe (9) ends are positioned withinthe cones (115), the previously described rotators (50 a-c) can rotatethe pipe (9) at a desired speed.

The coating material usable with the powder coating system (10) can be athermosetting or thermoplastic compound that can fusion bond to theinner surface or wall of a pipe (9) when heated above the fusiontemperature of the coating material. The material can be comminuted to apowder of a particle size(s) that will be supported by the gas orairflow rate within the pipe. For purposes of this application, gasshall include any gaseous mixture which may include fluids and smallparticles, for example, air. As further illustrated in FIGS. 3A and 3B,the powder coating system (10) can comprise a generally rectangularcontainer for the coating material, called a fluid bed (160). The fluidbed can comprise a coating material container (165) and a cover (166)with an aperture (167) therein to admit the coating material into thecoating material container (165). Inlets (163) in the base of fluid bed(160) allow air or other gas(es) to be introduced into the gas receivingchamber (164), located below the coating material container (165). A gaspermeable membrane (not shown) can keep the coating material out of gasreceiving chamber (164) while allowing gas to enter the bottom of thecoating material container (165). As a result of the introduction of gasinto the fluid bed (160), coating material can be aerated and can behavemuch as a fluid. Furthermore, an outlet port (168) is shown located lowon the side of the fluid bed (160) and above the permeable membranes,with a quick shut-off valve (171) connected at the outlet port (168).The quick shut-off valve (171) can be operated by any means in the art,including a fluid rotary actuator (172), depicted in FIG. 3A.

Pressurized air can be introduced into the air receiving chamber (165)by a conduit (161) extending from an air manifold (150), which canreceive compressed air from a compressor (not shown) by an air supplyconduit (155). FIG. 3A further depicts a diaphragm type air pressureregulator and flow shut-off combination valve, referred to as a pressureand flow regulator (162), which is adapted for both regulatingdownstream pressure and independently shutting off gas flowtherethrough. The pressure and flow regulator can be actuated to theopen or closed position by an electrical coil or by any other meansknown in the art, including a fluid rotary actuator. Although thepressure and flow regulator (162) is depicted as a single member, inother embodiments of the powder coating system (10), the pressureregulator and the fluid flow shut-off valve of the pressure and flowregulator (162) can be separate devices that can be connected in line.It should be noted that any of the pressure and flow regulators,described hereinafter, can be replaced by individual pressure regulatorsand shut-off valves and that any of the pressure and flow regulators,described hereinafter, can be actuated by any means known in the art.Using pressure and flow regulators, a predetermined and adjustableamount of gas, such as air at regulated pressures, can be introducedinto the system in accordance with the desired operation.

The powder coating system (10), including the various pressure and flowregulators disclosed herein, can be governed by a programmablecontroller or computer (not shown), which receives informationconcerning the length of the pipe (9) to be coated as well as thediameter of the pipe (9); and then, the controller or computer signalsthe various shut-off valves and pressure and flow regulators as to thelength of time, the amount of pressure, and in what particular sequencethe valves and regulators should be opened. Additionally, the shut-offvalve (171) can be opened according to the specific requirements of eachpipe, for various lengths of time, thereby admitting the appropriateamount of coating material for each pipe (9).

Further depicted in FIGS. 1 and 3C, is a coating material storage hopperassembly (200) used to store the coating material and dispense thecoating material into the fluid bed (160) as the coating material isused during the course of the coating operations. The storage hopperassembly (200) can comprise a main container (201) supported above thefluid bed (160) by a frame (205). The main container (201) can includeupper doors (202) to enclose the coating material within the maincontainer (201). The main container (201) can be positioned above thefluid bed (160) for conveniently dispensing the coating materialtherein. A gate valve (207), which can be operated by a motor or a fluidrotary actuator, is further shown at the bottom of the storage hopper(201). The gate valve (207) can be used to feed the coating materialinto the fluid bed (160) through the aperture (167) in the cover (166).FIG. 1 further depicts a return tube (210), connecting the back end ofthe coating barrel (120) with the main container (201) of the hopperassembly (200). During coating operations, the quick shut-off valve(125) can be opened to allow air and any excess coating material, notused up to coat the pipe (9) or directed into the collection hopper, toflow through the return tube (210) and into the main container (201) tobe reused. As shown in FIGS. 3B and 3C, the bottom of the return tube(210) can extend below the quick shut-off valve to form a particlecollector (211), which can collect the larger pieces of coating materialthat are too heavy and/or too large to be transferred back into the maincontainer. The particle collector (211) can comprise a bottom plug (212)that can be opened to clean out the particle collector (21).

As further illustrated in FIGS. 3A, 3B, and 3C, attached to the quickshut-off valve (171) is a tubular inlet conduit, which is referred to asa feed tube (170) that can be usable for introducing or feeding thecoating material from the fluid bed (160) into a centrally positionedelongated tubular member, referred to as the coating barrel (120),during coating operations. The feed tube (170) is shown connected withthe coating barrel (120) at a negative angle with respect to a verticalaxis, wherein the feed tube (170) can be angled slightly backwards atthe junction with the coating barrel (120). However, in anotherembodiment of the coating system (10), the feed tube (170) can beconnected with the coating barrel (120) at a 90 degree angle, or otherangle for permitting the connection. The coating barrel (120) isdepicted having a generally straight configuration with a bore extendinglongitudinally therethrough along the central axis ((5), see FIG. 5)thereof.

The feed tube (170) can further contain, adjacent to the shut-off valve(170), an internal nozzle (175), directed along the central axis of thefeed tube (170), away from the fluid bed (160), for drawing coatingmaterial from the fluid bed (160). The internal nozzle (175) can providea push-pull effect on the coating material in the fluid bed (160) whenthe shut-off valve (171) is opened. While the pressure inside the fluidbed (160) pushes the coating material into the feed tube (170), the airflow from the internal nozzle (175) can generate suction to further drawthe coating material from the fluid bed (160). The air flow within thefeed tube (170) can promote air suspension of the coating materialparticles, thus forming a “cloud” of particles of coating material.

Pressurized air can be supplied to the nozzle (175) by a fluid conduit(154), wherein the air pressure and flow can be controlled by a pressureand flow regulator (159) connected to the air manifold (150). When theshut-off valve (171) and the pressure and flow regulator (159) areopened for a predetermined period of time, a predetermined amount offluidized coating material can be drawn from the fluid bed (160), by theair flow generated by the nozzle (175), and communicated through thefeed tube (170) into the coating barrel (120). The coating barrel (120)is shown extending the length of the first coating apparatus (100 a),wherein the first end (e.g. front end) of the coating barrel (120) canbe connected to the rotating joint (116), and the second end (e.g., backend) of the coating barrel (120) can have a quick shut-off valve (125)attached thereto, to open and close the second end of the coating barrel(120) and to connect with the coating material return tube (210). Thequick shut-off valve (125) can be operated by any means in the art,including a fluid rotary actuator (126).

FIGS. 3A and 3C further depict three air supply conduits (141, 142, 143)that can be connected to the coating barrel (120), toward the second endof the coating barrel (120). The air supply conduits introducepressurized air into the coating barrel (120) for moving the coatingmaterial out of the coating barrel (120) after the coating material isintroduced into the coating barrel (120) from the fluid bed (160). Thedepicted conduits (141, 142, 143) can comprise different diameters ofpipe to supply different volumetric flow rates of pressurized air intothe coating barrel (120), wherein the larger conduit (143) can supply alarger quantity of air than the medium conduit (142), and wherein themedium conduit can supply a larger quantity of air than the smallerconduit (141). The conduits (141, 142, 143) can receive air from an airtank (140), which can store pressurized air that is supplied from thecompressor (not shown). Each conduit (141, 142, 143) can comprise apressure and flow regulator (146, 147, 148) along the length thereof,between the air tank (140) and the coating barrel (120), wherein eachpressure and flow regulator (146, 147, 148) can be appropriately sizedfor each conduit (141, 142, 143). During coating operations, thepressure and flow regulators (146, 147, 148) can be opened or closedindividually or in combinations, to supply the appropriate volumetricflow rate into the coating barrel (120). If larger volumetric flow ratesare needed, because, for example, a large diameter pipe is being coated,a combination of two or all three pressure and flow regulators can beopened to communicate air from the air tank (140) to the coating barrel(120). Air can be communicated from the compressor to the air tank (140)through the main air supply conduit (155), the air manifold (150),and/or an intermediate conduit (144) extending between the air manifold(150) and the air tank (140). The air pressure inside of the air tankcan be controlled by a pressure regulator (145).

Referring again to FIGS. 3B and 3C, the Figure depicts a collectionhopper (180) connected to the coating barrel (120), adjacent to theshut-off valve (125). A tubular segment (187) is shown connecting thecollection hopper (180) to the coating barrel (120), and another tubularsegment (186) is shown connecting the collection hopper (180) with avacuum generator (185). In an embodiment, the vacuum generator (185) canbe one unit (as shown). In an alternative embodiment, the vacuumgenerator can be a plurality of vacuum generators (not shown) workingseparately or together in accordance with the design and operationalneeds of the operator. The vacuum generator or vacuum generators can beengineered to be on different sections of the apparatus and not just asshown in FIGS. 3B and 3C. During coating operations, the vacuumgenerator (185) can draw air and excess coating material that isentering the coating barrel (120) at the end of each coating cycle. Ashut-off valve (184) can be opened with a rotary actuator (182B) toallow the air and the coating material to be drawn from the coatingbarrel (120) and to flow through the collection hopper (180). When theshut-off valve (184) is opened, the drawn coating material is filteredout by an internal filter (not shown), located within the collectionhopper (180), so that none of the excess coating material or coatingmaterial byproducts are released into the atmosphere. The internalfilter can be removed and replaced after being cleaned. Once thecollection hopper (180) is filled with unused coating material, a rotaryactuator (182A) can be actuated to open the shut-off valve (181) toallow most of the coating material to be evacuated from the collectionhopper (180).

Referring again to FIG. 3A, individual nozzles, within each set ofnozzles (121, 122, 123), can be interconnected by conduits (151, 152,153), which extend between each nozzle so that the gas or air pressure,supplied to each nozzle of a particular set of nozzles (121, 122, 123),is the same. Furthermore, the size, airflow characteristics, and airflow direction of each nozzle of each set of nozzles (121, 122, 123) canbe similar or the same so that each nozzle of each set of nozzles (121,122, 123) can cooperatively and uniformly induce the desired deflectionof air flow within the coating barrel (120). As further depicted inFIGS. 3A, 3B, and 3C, conduits (151, 152, 153) further connect each setof nozzles (121, 122, 123) with the air manifold (150). Pressure andflow regulators (156, 157, 158) control the pressure and flow of airinto the sets of nozzles (121, 122, 123), allowing each set of nozzles(121, 122, 123) to be set to operate at different pressures or to beshut-off independently of the other set of nozzles (121, 122, 123).

Referring also to FIG. 4, the Figure depicts a cross-sectional view ofthe coating barrel (120) and the first set of gas nozzles (121).Specifically, the Figures show the powder coating system (10) with thecoating barrel (120) having three sets of gas nozzles (121, 122, 123)positioned along the length thereof, wherein each set of nozzles (121,122, 123) can be axially spaced along the coating barrel (120) betweeneach end. Each set of nozzles (121, 122, 123) is shown having threeindividual nozzles circumferentially spaced at 120 degree intervalsabout the central axis (5) of the coating barrel (120). Each nozzle(121, 122, 123) can be selectively oriented to direct a jet of air intothe central bore of the coating barrel (120), at a diagonal angle withrespect to the central axis (5), to cause the air flowing therethroughto flow in a spiral manner, comprising both axial and circumferentialflow components.

In an embodiment, the pitch of the nozzles (121, 122, 123) can beselectively adjusted to direct a jet of air into the central bore of thecoating barrel (120), at a desired diagonal angle with respect to thecentral axis (5). As discussed above, this causes the gas or air flowingtherethrough to flow in a spiral manner, comprising both axial andcircumferential flow components, which mixes the powder and the gas. Thepitch of the nozzle influences the amount of mixing between the powderand gas and adhesion with the tubular. Typically, all three nozzles(121, 122, 123) are oriented 30 degrees toward the rotatable cone 115.Orienting the pitch of one or more of the nozzles more toward therotatable cone 115 will reduce the mixing between the powder and gas andreduce adhesion with the tubular. Conversely, orienting the pitch of oneor more of the nozzles (121, 122, 123) toward the feed tube 170 wouldresult in increased mixing between the powder and gas and increasedadhesion with the tubular. In one embodiment, any nozzle can be adjustedmanually by opening and adjusting a bezel on any one of the nozzles(121, 122, 123).

In various embodiments, the pitches of the nozzles could be operatedindividually or in concert. For example, a bell crank can adjust onenozzle individually, two nozzles, or all three nozzles together byhaving the bell crank connected to one, two, or all three nozzlesrespectively. In one embodiment, the adjustment by the operator can beautomated wherein each nozzle can be controlled by a controllercontrolling at least one or a plurality of separate nozzle motors. Thecontroller for the nozzles can be connected to the nozzle motors 199with wires or through wireless communication. A computer running aprogram to operate the controller adjusting the pitch of nozzles (121,122, 123) can be utilized to determine the most favorable pitch angle ofthe nozzles based on operating conditions and desired properties of thecoating materials. The computer program could also be used toautomatically, in real time, adjust the nozzles (121, 122, 123) based onthe operating conditions to obtain favorable coating materialproperties.

The word “spiral” describes the shape of the air flow and the shape ofthe flow of the coating material through the coating barrel (120). Asused herein, the word spiral refers to a helical or coiled shape.Specifically, the spiral movement has a longitudinal or axial componentand a tangential or circumferential component. The coating material canmove tangentially with respect to the central axis (5) at the insidesurface of the coating barrel (120), wherein the inside surface of thecoating barrel continually redirects the gas and coating material flowcircumferentially along the inside surface of the coating barrel (120).The coating material can also move axially, wherein the coating materialcan flow along the inside surface of the coating barrel (120), along adirection parallel to the central axis (5) and toward the front end ofthe coating barrel (120). As the shape of the spiral movement issubstantially circular or ring like, centrifugal force will maintain thecoating material particles at or near the inside surface and away fromthe center or axis of the coating barrel (120) and the tubulars beingcoated. Therefore, because of the spiral movement, the density of thecoating material particle cloud can be less, along the central axis (5)of the coating barrel (120) and the tubular being coated, than along theinside diameter or inside wall surface thereof.

During each coating sequence, pressurized air from the conduits (141,142, 143) enters the coating barrel (120) and moves toward the front endof the coating barrel (120). The air is then deflected by directionalair jets from the three sets of nozzles (121, 122, 123), resulting inspiral air movement as previously described. As the air flows though thecoating barrel (120) in a spiral manner, toward the front end of thecoating barrel (120), the air encounters the coating material particlesthat are entering the coating barrel (120) and deflects the coatingmaterial in the spiral direction. As the cloud of coating materialspirals further downstream and past the nozzles (121, 122, 123), thespiral flow of coating material can be successively adjusted to comprisea greater circumferential flow component or a greater axial flowcomponent. As the cloud of coating material exits the coating barrel(120), the cloud of coating material then spirals into the rotatablecone (115) and into the pipe (9) positioned within the cone (115).

The pipe (9) can be rotated in the opposite direction to thecircumferential component of the spiral movement of the coatingmaterial. This increases the relative tangential or circumferentialvelocity of the coating particles at the inside surface of the pipe (9),and reduces dwell or residence time of the coating material particles ata given point on the inside surface of the pipe, whereby at higher airvelocities, less coating is deposited on the hot pipe (9).

Referring again to FIG. 4, the Figure shows a cross sectional view of anembodiment of the coating barrel (120), which includes a cross sectionalview of individual nozzles (121 a-c) of the first set of nozzles (121).Each nozzle (121 a-c), including the first nozzle (121 a), comprises anozzle body (190), which can be pivotally positioned within a hole inthe wall of the coating barrel (120). The hole in the wall can beadapted to receive the nozzle body (190) and to allow the nozzle body(190) to pivot freely therein. The nozzle body (190) is further showncomprising a shoulder (191) positioned flush against the outer surfaceof the coating barrel (120). The outer surface of the coating barrel(120), adjacent to the hole in the wall of the coating barrel (120), canbe flattened to facilitate flush contact of the shoulder (191) and thecoating barrel (120) for preventing air from leaking therebetween. Thenozzle body (190) can comprise a nozzle outlet (193) that can be adaptedto direct air in a diagonal direction with respect to the vertical axis(6), which extends vertically through the center of the coating barrel(120). Although the nozzle outlet (193) is shown aligned at about a 45degree angle with respect to the vertical axis (6), the nozzle body(190) can be constructed having other angles with respect to thevertical axis (6) to create spiral air flow within the coating barrel(120).

FIG. 4 further depicts a bezel (192) connected to the coating barrel(120) with bolts to capture the shoulder (191) of the nozzle body (190)beneath the bezel (192). The bezel (192) can compress the shoulder (191)against the coating barrel (120) wall, when the bolts are tightened, toprevent rotation or pivoting of the nozzle body (190). As furtherdepicted in FIG. 4, the inner surface of the nozzle body (190) can beflush with the inside surface of the coating barrel (120) to prevent airdrag or to minimize disturbance to the flow of air through the coatingbarrel (120). To adjust the direction or the angle of the nozzle outlet(193) in relation to the central axis (5), the bolts of the bezel (192)can be loosened, the nozzle body (190) can be rotated to a desired anglebetween the nozzle outlet (193) and the central axis (5), and the boltscan be re-tightened.

The present disclosure is further directed to an embodiment of a methodor a process for coating the pipe (9) with the coating apparatus (10)described above. Prior to the start of the coating operations, thedimensions of the pipe (9), such as a length, an inner diameter, and anouter diameter, can be entered into the powder coating system (10)controller or computer (not shown) to calculate the amount of coatingmaterial that will be required to coat each pipe (9). The pipedimensions can be used by the controller to control the operation of theplurality of motors, linear actuators, rotary actuators, and pressureand flow controllers in order to properly coat the pipe (9). Once theamount of coating material, which is needed to coat the specified pipe(9) to a given millage or thickness, is calculated, this and other datacan be entered into the programmable controller to execute the coatingsequence, which includes controlling variables such as volumetric airflow through the coating barrel (120), the amount of coating materialthat should be injected into the coating barrel (120), the amount oftime that each shut-off valve should be opened or closed, and therotting speed of the pipe (9). Prior to commencement of the coatingoperations, all the shut-off valves can be actuated or set to the closedposition to prevent air flow therethrough.

Before the coating stage of the pipe coating process can start, the pipecan be heated to a desired temperature and ejected from the oven (notshown) onto pipe storage rack (not shown) or another pipe storagestructure. The pipe can then be properly positioned for coating, betweenthe cones (115) of the first and second coating apparatus (100 a, 100 b)and between the wheels (56) of opposite roller assemblies (55) on eachrotator (50 a-c), as depicted in FIG. 1. To properly position the pipe(9) for coating, the pipe can be first moved from the pipe storage rackand positioned on the upper edge (71) of the arms (70) of the first,second, and third rotators (50 a, 50 b). As the upper edges (71) of thearms (70) are sloping, the pipe (9) can roll along the upper edges (71)until the pipe (9) is stopped by the edge (74) of the extending members(73). Thereafter, the hydraulic cylinders (77) can retract to lower thearms (70) and position the pipe (9) between the wheels (56) of theopposite roller assemblies (55). Prior to positioning of the pipe (9)between the wheels (56), the spacing between the wheels (56) can be setby the linear slide assemblies (60), based on the preprogrammed physicaldimensions of the pipe (9), whereby the pipe (9) can be positioned orwedged between the wheels (56), yet remain on top of the wheels (56) andnot fall through or into the space between the wheels into contact withthe arms (70). Once the pipe (9) is positioned between the wheels (56)of the rotators (50 a-c), the first and/or the second coating apparatuscan move toward each other to capture the pipe (9) between the opposingcones (115). The motors (57) in each rotator (50 a-c) can then beenergized to rotate the pipe (9) and the cones (115), and the pipe isnow ready for the coating sequence.

In order to evenly coat the pipe (9) with the coating material, thepowder coating system (10) can be used by performing several specificsteps or actions listed below. Referring again to FIGS. 3A, 3B, and 3C,the coating stage of the coating process can begin by establishing thespiral air flow inside the coating barrel (120) of the first coatingapparatus (100 a) and the pipe (9) being coated. This may be achieved byturning on the compressor (not shown) to store pressurized air or gas inthe air tank (140) and, based on the diameter and length of the pipe(9), open one or more pressure and flow regulators (141, 142, 143) tofeed pressurized air into the coating barrel (120). Furthermore, thepressure and flow regulators (156, 157, 158) of the first coatingapparatus (100 a) can be opened to feed pressurized air into the threesets of nozzles (121, 122, 123) to induce spiral motion into the airflowing through the coating barrel (120). Lastly, the vacuum generator(185) of the second coating apparatus (100 b) can be turned on and theshut-off valve (184) can be opened to draw air from the pipe (9) intothe coating barrel (120) of the second coating apparatus (100 b). Thepressure and flow regulators (141, 142, 143, 156, 157, 158) can bemanually preset to a desired pressure to control the air pressure at theoutlet of the pressure and flow regulators. In other embodiments (notshown) of the powder coating system (10), the outlet air pressure of thepressure and flow regulators (141, 142, 143, 156, 157, 158) can beelectronically and/or remotely controlled by a controller and/orcomputer.

Once spiraling air flow is introduced in the pipe (9), the coatingmaterial can be introduced into the coating barrel (120) of the firstcoating apparatus (100 a). Specifically, the rotary actuator (172) canopen the shut-off valve (171) as the pressure and flow control valve(159) is opened to force air out of the internal nozzle (175).Simultaneously, the pressure and flow control valves (146, 147, 148) canbe closed to prevent the introduction of air flow through conduits (141,142, 143). Accordingly, the coating material is drawn from the fluid bed(160) and pushed though the feed tube (170) into the coating barrel(120) of the first coating apparatus (100 a). As the coating materialenters the coating barrel (120), the three sets of nozzles (121, 122,123) induce the air and the coating material located inside the coatingbarrel (120) to spiral therein. Once a predetermined amount of coatingmaterial has been introduced into the coating barrel (120), the shut-offvalve (171) is closed, preventing an inflow of the coating material.

The coating material, travelling in a spiral manner, will be forcedoutward and will expand outwardly immediately after exiting the firstend of the coating barrel (120). The spiral motion can cause the coatingmaterial to move radially, as the coating material moves axially throughthe pipe (9), to coat the inside surface of the pipe with the coatingmaterial. As the spiraling cloud of coating material enters and movesthrough the pipe (9), the coating material settles and coats the insidesurface of the pipe (9). Once all of the coating material moves from thecoating barrel (120) into the pipe (9), the pressure and flow valves(156, 157, 158) can be closed to shut off flow to the nozzle sets (121,122, 123).

Thereafter, as the cloud of coating material continues to move throughthe pipe (9) and reaches a mid-point along the length of the pipe, thecloud of coating material can be moved further by increasing the backpressure (e.g., pressure upstream from the moving coating material,pressure in the first coating apparatus (100 a)) and shutting offsuction generated by the second coating apparatus (100 b). Specifically,when the cloud of coating material reaches about the mid-point along thelength of the pipe (9), several actions can be performed at essentiallythe same time. First, the back end shut-off valve (125) of the secondcoating apparatus (100 b) can be opened to allow any excess coatingmaterial particles to be deposited in the main container (201) of thefirst coating apparatus (100 a). Second, one or more of the pressure andflow valves (146, 147, 148), of the first coating apparatus (100 a), canopen to introduce pressurized air into the coating barrel (120) formoving the coating material further through the coating barrel (120).Third, the vacuum shut-off valve (184) of the second coating apparatus(100 b) can close to turn off suction at the coating barrel (120) of thesecond coating apparatus (100 b). As the cloud of the coating materialmoves past the midpoint, along the length of the pipe (9), the coatingmaterial continues to adhere to the inside surface of the pipe untilmost or all of the coating material is used up, marking the end of thefirst coating cycle.

The second coating cycle can be the same or similar to the first coatingcycle. Specifically, the sequence of steps described above can beperformed by the opposite coating apparatus (100 a, 100 b), wherein thesteps previously performed by the first coating apparatus (100 a) can beperformed by the second coating apparatus (100 b), while the stepspreviously performed by the second coating apparatus (100 b) can beperformed by the first coating apparatus (100 a). Once the secondcoating cycle is complete, the inside surface of the pipe (9) is coatedwith a second coat of the coating material and the pipe (9) can beremoved from the rotators (50 a-c).

Once the pipe (9) is ready for removal, the coating apparatus (100 a,100 b) can roll away from each other, freeing the pipe (9) from thecones (115). Once again, the arm (70) can be lifted by the cylinders(77) until the upper edge (75) of the extending members (73) contact andlift the pipe (9). Once the pipe (9) clears the wheels (56), the pipecan roll along the upper edges (75, 71) until it rolls off the arm (70)and onto a collection rack or other container (not shown). A newuncoated pipe (not shown) can then be positioned on the rotators (50a-c), and the first and second coating cycles can be repeated.

While various embodiments usable within the scope of the presentdisclosure have been described with emphasis, it should be understoodthat within the scope of the appended claims, the present invention canbe practiced other than as specifically described herein. It should beunderstood by persons of ordinary skill in the art that an embodiment ofpowder coating system (10) in accordance with the present disclosure cancomprise all of the features described above. However, it should also beunderstood that each feature described above can be incorporated intothe powder coating system (10) by itself or in combinations, withoutdeparting from the scope of the present disclosure.

What is claimed is:
 1. A system for moving and rotating cylindricalmembers during coating and cleaning operations, the system comprising: afirst rotator apparatus and a second rotator apparatus positioned at adistance from each other, wherein each of the first and the secondrotator apparatus comprise: a first wheel having a first axis ofrotation and a second wheel having a second axis of rotation, whereinthe first and second axes of rotation are generally parallel; and an armpositioned adjacent the first and second wheels, wherein the arm extendsgenerally perpendicularly with respect to the first and second axes ofrotation, wherein the arm has a downwardly sloping upper edge, whereinthe arm is movable in an upward direction and a downward direction,wherein the arm receives a cylindrical member thereon, wherein the armmoves in the downward direction to position the cylindrical memberbetween the first and the second wheels, wherein the arm moves in theupward direction to move the cylindrical member from between the firstand the second wheels.
 2. The system of claim 1, wherein the firstrotator further comprises at least one linear actuator for moving thearm in the upward direction or the downward direction.
 3. The system ofclaim 1, wherein the arm further comprises along the upper edge thereofa protruding member extending in the upward direction, wherein theprotruding member stops the cylindrical member from rolling about theupper edge of the arm.
 4. The system of claim 1, wherein the first wheeland the second wheel are movable toward each other or away from eachother to accommodate the cylindrical member therebetween.
 5. The systemof claim 1, wherein the second rotator apparatus further comprises aframe operatively connecting the first wheel, the second wheel, and thearm, wherein the second rotator apparatus is movable horizontally towardthe first rotator apparatus or away from the first rotator apparatus toaccommodate a length of the cylindrical member.
 6. A method for movingand rotating a tubular member during coating and cleaning operations,the method comprising the steps of: providing a first rotator apparatuscomprising a first set of wheels and a first arm positioned adjacent tothe first set of wheels, wherein the first arm has a first upper edgethat is downwardly sloping; providing a second rotator apparatuscomprising a second set of wheels and a second arm positioned adjacentto the second set of wheels, wherein the second arm has a second upperedge that is downwardly sloping; positioning a tubular member on thefirst upper edge and the second upper edge; rolling the tubular memberalong the first and the second upper edges from a first side of thefirst arm and the second arm toward the second side of the first arm andthe second arm; stopping the tubular member from rolling along the firstarm and the second arm at an intermediate position between the firstside and the second side of the first arm and the second arm; moving thefirst arm and the second arm in a downward direction to position thetubular member in contact with the first set of wheels and the secondset of wheels; rotating the first set of wheels and the second set ofwheels to rotate the tubular member; moving the first arm and the secondarm in an upward direction to lift the tubular member off of the firstset of wheels and the second set of wheels; and rolling the tubularmember along the first upper edge and the second upper edge toward thesecond end of the first arm and the second arm for removal of thetubular member from the first and the second rotator apparatus.
 7. Themethod of claim 6, wherein the first arm and the second arm arepositioned generally perpendicularly with respect to a first axis and asecond axis of rotation.
 8. The method of claim 6, wherein the step ofstopping the tubular member from rolling along the first arm and thesecond arm at the intermediate position between the first and the secondsides of the first arm and the second arm comprises stopping the tubularmember from rolling along the first arm and the second arm at anintermediate position between the first and the second sides of thefirst arm and the second arm, with a protruding member extendingupwardly from each of the first and the second upper edges.
 9. Themethod of claim 6, further comprising the step of moving at least one ofthe first and the second sets of wheels toward or away from the other toaccommodate an outer diameter of the tubular member.
 10. The method ofclaim 6, further comprising the step of moving the at least one of thefirst and the second rotator apparatus toward or away from the other toaccommodate a length of the tubular member.
 11. A method for coating aninterior surface of a tubular member, wherein the method comprises thesteps of: capturing the tubular member between a first conical memberand a second conical member, wherein the first conical member isconnected with a first tubular barrel of a first coating apparatus,wherein the second conical member is connected with a second tubularbarrel of a second coating apparatus; rotating the tubular member;establishing a swirling air flow through the first tubular barrel with aplurality of nozzles positioned along the tubular barrel; drawing airfrom the second tubular barrel with at least one vacuum generator;introducing coating material into the first tubular barrel, whereby theswirling air flow moves the coating material through the tubular memberin a swirling manner; communicating air into the first tubular memberthrough an air conduit connected to the first tubular member upstreamfrom the plurality of nozzles to move the coating material through thetubular member to coat the tubular member; and adjustably controlling avolumetric flow rate of the air communicated into the first tubularmember through the air conduit.
 12. The method of claim 11, wherein thestep of introducing air flow into the first tubular member upstream fromthe plurality of nozzles comprises opening at least one flow controlvalve of a plurality of flow control valves to introduce a desiredvolumetric air flow into the first tubular member upstream from theplurality of nozzles.
 13. The method of claim 11, further comprising thestep of moving the coating material, with the air communicated into thefirst tubular member through the air conduit, through the second tubularconduit into a storage container.
 14. The method of claim 11 furthercomprising the step of adjusting at least one pitch of the plurality ofnozzles to obtain favorable properties of the coating materials.
 15. Themethod of claim 11 wherein the at least on vacuum generator comprises aplurality of vacuum generators.